Amphenol PowerLok 10.0 User manual

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PowerLokTM 10.0 单芯95mm2直头插头组装规范
PowerLokTM 10.0 1 POS 95mm2 180D Plug
Assembly Manual
Manual P/N：8P1143
Rev.01 20210611
键位
X 键
Y 键
U 键
V 键
W 键
T键
Key
X
Y
U
V
W
T
高压互锁
0：无
1：有
HVIL
0：No
1：Yes
线缆大小
Cable Size
mm2
95
线缆类型
Cable type
H+S cable
PL18(X)-30(X)-95-5

01/05
Manual P/N：8P1143 _ Rev.01 20210611
PowerLokTM 10.0 单芯95mm2直头插头组装规范 PowerLokTM 10.0 1 POS 95mm2 180D Plug Assembly Manual
第一部分：包装清单
Part 1：Package contents
①屏蔽壳组件 Shield shell assembly ×1
②带高压互锁弹片的绝缘筒 Insulation sleeve with HVIL contact spring ×1
（300系列无高压互锁弹片 No HVIL contact spring for 300 series）
③R4端子组件 R4 terminal Assy ×1
④定位套 Position sleeve ×1
⑤内铜套 Inner metal gasket ×1
⑥外铜套 Outer metal gasket ×1
⑦密封圈 Sealing ×1
⑧尾盖 End cap ×1
①②③④
⑤⑥⑦⑧

安装步骤 Assembly Instruction
表1 : 剥皮尺寸
Table 1: Strip length
02/05
Manual P/N：8P1143_ Rev.01 20210611
步骤1：取出连接器, 如上页图示拆开零件
Step1：Take out the connector and take it apart as the picture shown on the previous page.
步骤2：选取合适线缆(参考手册最后的附录），按照表1尺寸剥离绝缘皮和外皮
Step2：Select the right cable(refer to the appendix), prepare the cable according to the sketch and Table 1 below
线材尺寸
Cable Size A (mm) B (mm)
95mm² 18±1 27 ±1
A
B
步骤3：取各1pcs的⑧尾盖, ⑦密封圈 Sealing和⑥外铜套, 依次穿过线缆。
Step3：Take each 1pcs of ⑧end cap, ⑦Sealing and ⑥Outer metal gasket and make them through the cable in
turn as shown in the picture below.
凹面 concave ⑦密封圈
Sealing ⑧尾盖
end cap
⑥外铜套
Outer metal
gasket
屏蔽包上美纹纸避免尾盖内密
封胶圈损伤
The braiding is covered with
paper to avoid damage to the
sealing ring inside the end
cap
步骤4：将编织均匀打散反折，取1PCS的⑤内铜套压入编织上，再将编织反折在其上，如图示修剪平齐，
再将外铜套压紧在内铜套上如图示。
Step4：Scatter and fold the braiding evenly, Take 1PCS of ⑤inner metal gasket onto the braiding, then fold the
braiding onto it. Trim it flat as shown in the figure.
Then press the outer metal gasket on the inner metal gasket as shown in the figure.
⑤内铜套
Inner metal
gasket
8~9mm
注意此处长度保持不变
keep length in the
same here
A B
导体
conductor 外被
Jacket
编织
Braiding
绝缘皮
insulation
PowerLokTM 10.0 单芯95mm2直头插头组装规范 PowerLokTM 10.0 1 POS 95mm2 180D Plug Assembly Manual

步骤6：调试好免换模压接机BZW-6C，将端子压接在线材上(详细规格参照手册最后的附录）
Step6：Set up the mould-free crimp machine BZW-6C, Then crimp the terminal on the wire.
(please refer to the appendix at the end of this manual for more crimping information)
步骤5：如图示穿入④定位套，再穿入③ R4端子组件并推到底，
Step6：Push into the ④position sleeve, then push into the ③R4 terminal assembly and push to the bottom, as
shown in the figure.
⑴建议使用附录中的线材，如果要使用其它的线材，请联系当地销售，让他们提供延伸的产品
Cables written in the appendix are highly recommended for crimping, please contact our local sales for help if you want to use other cables out
of this table
⑵客户需要重新确认压接区域横截面和拉力测试，这两项达到压接的质量标准，端子压接需要满足压缩比要求：80-90%
A good crimping process is determined by 3 factors: W、H and tensile test result, please confirm these 3 targets specified are met after
crimping, Terminal crimping needs to meet the compression ratio requirements: 80-90%.
⑶横截面仅供参考，客户负责采购压接工具或刀模
Cross section shape is only for reference, all crimping tools needed are supposed to be prepared by customers
端子压接高宽度尺寸，“W”:为压接宽度，“H”为压接高度（压接高宽度尺寸及拉力标准参考手册后的附录）
Terminal crimping quality depends on 2 parameters: "W" crimping width and "H" crimping height.( Please refer to the
appendix at the end of this manual for details)
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Manual P/N：8P1143_ Rev.01 20210611
步骤7：插入R4 holder到②绝缘筒上, 转动使其触底
Step7：Bring ②insulation sleeve through R4 holder and rotate ②insulation sleeve until it arrives at a stop
position
步骤8：将半成品如下图示插入①屏蔽壳组件， 注意方向正确，防止损伤HVIL弹片，插到底后将密封圈推到位，
固定外壳与电缆，以10~12N∙m拧紧尾盖，完成此端线束组装。
Step8：Insert the semi-finished product into ①Shield shell assembly as shown below, pay attention to the
correct direction to prevent damage to the HVIL contact spring, then insert it into the end, push sealing into its
place, fix the housing and cable, tighten the end cap with 10~12N∙m, and complete assembly of the wire harness
at this end .
③R4端子组件
R4 terminal Assy
④定位套
Position sleeve
②绝缘筒
Insulation sleeve
确保R4尾部可见
Make sure R4 end visible
横截面
Cross section
H
W
PowerLokTM 10.0 单芯95mm2直头插头组装规范 PowerLokTM 10.0 1 POS 95mm2 180D Plug Assembly Manual

步骤9：建议客户参考下面的测试参数，对线束进行绝缘电阻测试和耐压测试
Step9：Insulation resistance and dielectric withstand voltage tests are obligated to be done according to below test
parameters to guarantee the good electric performance of the whole harness
9-1 绝缘电阻测试
9-1 Insulation Resistance Test
位置
Positions
测试电压
Test Voltage
测试时间（推荐）
Test Time（recommended)
绝缘电阻
Insulation Resistance
电缆芯线到壳体
Cable(power) to shell 1000 VDC 5S > 500 MΩ
电缆芯线到高压互锁
Cable(power) to HVIL 1000 VDC 5S > 500 MΩ
高压互锁到壳体
HVIL to shell 1000 VDC 1S > 100 MΩ
9-2 耐压测试
9-2 Dielectric Withstand Voltage Test
位置
Positions
测试电压
Test Voltage
测试时间（推荐）
Test Time（recommended)
漏电流
Leakage Current
电缆芯线到壳体
Cable(power) to shell 5000 VDC 10S <5mA
电缆芯线到高压互锁
Cable(power) to HVIL 5000 VDC 10S <5mA
HVIL to shell
高压互锁到壳体 500 VDC 1S <5mA
04/05
Manual P/N：8P1143 _ Rev.01 20210611
9-3 测试说明:
警告: 建议的电气测试及其参数应根据终端应用要求进行审查，以确保安全性并防止损坏其他部件。提供的参
数是基于PowerLok连接器和其峰值1000VDC额定。提供的测试参数可能超出电缆组件或设备上使用的其他部
件/材料的限制。
9-3 Test note:
caution: Recommended electrical tests and their parameters should be reviewed against end
application requirements to ensure safety and to prevent damage to other components. Parameters
provided are based on the PowerLok connectors and their peak 1000VDC rating. Test parameters
provided may exceed the limit of other components/materials used on the cable assembly or device.
将密封圈推到底
Push the sealing to the bottom
①屏蔽壳组件
Shield shell assembly
HVIL 弹片
位置
HVIL
contact
spring
position
PowerLokTM 10.0 单芯95mm2直头插头组装规范 PowerLokTM 10.0 1 POS 95mm2 180D Plug Assembly Manual

线缆压接的参考规范 Reference specification for cable crimping
附录APPENDIX
线缆压接的参考规范
Reference specification for cable crimping
05/05
Manual P/N：8P1143_ Rev.01 20210611
线缆型号
Cable Type 电线尺寸 Cable Size
导体结构
(mm)
Conductor
导体外径
(mm)
Conductor
OD
电线外径
(mm)
Wire OD
压接高度H(mm)
Crimping
height
压接宽度
W(mm)
Crimping Width
参考保持力
Retention
Force
HS 84100299 95mm² 480*0.51 13.5 Max 19.9±0.4 15.0±0.3 17.3±0.3 4200N
版本记录 Revision history
序号
Number 变更内容
Content of change
日期
Date
1 新出 New issue 20210611

Amphenol Technical Products International provides the above product specifications for the standard PowerLok™series
of connectors to assist users in identifying the correct product for the system to which the connectors may be applied. Specifications
are subject to change without notice. Contact your nearest Amphenol Corporation Sales Office for the latest specifications. All
statements, information and data given herein are believed to be accurate and reliable but are presented without guarantee,
warranty, or responsibility of any kind, expressed or implied. Statements of suggestions concerning possible use of our products are
made without representation or warranty that any such use is free of patent infringement and are not recommendations to infringe
any patent. Specifications are typical and may not apply to all connectors. Note that these specifications are derived from relevant
global standards used in the automotive and industrial transportation markets, but they are not a substitute for system level design
validation testing, which is the sole responsibility of the system designer and/or end user.
Asia Pacific
GuangZhou, China
Tel: [phone]
Add: 9th Floor, No. 10, the 4th Street, Kehui Jingu, Luogang District, Guangzhou ,Guangdong
P.C: 510663
North America
Winnipeg, Canada
Tel: [phone]
Add: 2110 Notre Dame Avenue
Europe
Milano, Italy
Tel: [phone]
Add: Via Barbaiana 5, 20020 Lainate(MI)
Email: [e-mail]
Asia Pacific
ChangZhou, China
Tel: [phone]
Add: No.11 Fengxiang Road, New District, Changzhou, Jiangsu
P.C: 213001